Hydrocarbon conversion catalyst and process using said catalyst



United States Patent 3,535,225 HYDROCARBON CONVERSION CATALYST AND PROCESS USING SAID CATALYST Joseph Jatfe, Berkeley, Calif., assignor to Chevron Research Company, San Francisco, Calif., a corporation of Delaware Filed Aug. 23, 1968, Ser. No. 754,787 Int. Cl. Cc 23/00 U.S. Cl. 208-59 14 Claims ABSTRACT OF THE DISCLOSURE and silica-alumina-zirconia gel; and processes using said catalyst.

INTRODUCTION This invention relates to catalytic hydrocracking of petroleum distillates and solvent-deasphalted residua to produce high-value fuel products including gasoline.

PRIOR ART It is known that a catalyst may comprise a crystalline zeolitic molecular sieve component associated with other catalyst components. It is also known that at least some of said other catalyst components may be in the form of a matrix in which the molecular sieve component is dispersed. It is also known that such catalysts may be used for such reactions as catalytic cracking, hydrocracking, and hydrodesulfurization. Representative prior art patents disclosing one or more of the foregoing matters include: U.S. Pat. 3,140,251; U.S. Pat. 3,140,253; British Pat. 1,056,301; French Pat. 1,503,063; and French Pat. 1,506,793.

There has been a continuing search for further improvements in such catalysts, and in similar multicomponent catalysts, particularly for hydrocracking uses.

IOBIECTS In view of the foregoing, objects of the present invention include providing an improved hydrocracking catalyst that has, compared with similar prior art catalysts:

(1) high hydrocracking activity; (2) high nitrogen tolerance; and (3) high hydrocracking stability.

It is a further object of the present invention to provide a hydrocracking process using said improved catalyst that is capable of producing excellent-quality gasoline and other valuable fuel products, and to provide methods of operating the hydrocracking process in an integrated manner with other process units to achieve various advantageous results.

The present invention will best be understood, and further objects and advantages thereof will be apparent, from the following description when read in connection with the accompanying drawing.

DRAWING In the drawing, FIG. 1 is a diagrammatic illustration of apparatus and flow paths suitable for carrying out the process of several of the embodiments of the present invention, including embodiments wherein a hydrofining zone precedes the hydrocracking zone, and embodiments wherein a selected fraction from the hydrocracking zone is catalytically reformed.

FIG. 2 is a diagrammatic illustration of apparatus and flow paths suitable for carrying out the process of additional embodiments of the present invention, including embodiments wherein a hydrofining zone precedes a hydrocracking zone in a single reactor shell, and embodiments wherein a selected fraction from the hydrocracking zone is catalytically cracked.

STATEMENT OF INVENTION In accordance with the present invention, it has been found that the foregoing objects are achieved by a hydrocarbon conversion catalyst consisting essentially of a unique combination of catalytic components, including a silica-containing gel, a Group VIII hydrogenating component and a crystalline zeolitic molecular sieve component that is substantially in the ammonia or hydrogen form and that is substantially free of any catalytic loading metal or metals.

More particularly, in accordance with the present invention there is provided a hydrocarbon conversion catalyst consisting essentially of (A) A gel matrix consisting essentially of: (a) a gel selected from silica-alumina gel, silica-alumina-titania gel and silica-alumina-zirconia; and (b) at least one hydrogenating component selected from Group VIII metals and compounds thereof; and

(B) A crystalline zeolitic molecular sieve substantially in the ammonia or hydrogen form, substantially free of any catalytic loading metal or metals, said molecular sieve further being in particulate form and being dispersed through said matrix; said catalyst further being characterized by an average pore diameter below 100 angstroms and a surface area above 200 square meters per gram.

Said matrix desirably will contain at least 15 weight percent silica, and suflicient alumina to provide an alumina-to-silica weight ratio of 15/85 to /20.

Said molecular sieve may be present in an amount of 1 to 50 weight percent, based on said catalyst.

When said matrix includes a silica-alumina-titania gel or a silica-alumina-zirconia gel, the titania or zirconia may be present in an amount of 1 to 15 weight percent of said matrix, calculated as metal.

Said Group VIII hydrogenating component may be, for example, nickel, cobalt, platinum or palladium, in the form of the metal, oxide, sulfide or any combination thereof. Said hydrogenating component may be present in an amount of 0.01 to 15 Weight percent, preferably 0.01 to 10 weight percent, based on said catalyst and calculated as metal. When said Group VIII hydrogenating component is nickel, cobalt or compounds thereof, preferably it will be present in an amount of at least 5 weight percent, based on said catalyst and calculated as metal. When said Group VIII hydrogenating component is platinum or palladium or compounds thereof, preferably it Will be present in an amount of less than 5 Weight percent, more preferably less than 3 weight percent, based on said catalyst and calculated as metal.

The Group VIII hydrogenating component is a catalytic metal, and the zirconium or titanium, when used, is not, and sodium is not, within the meaning of the term catalytic loading metal or metals, as used herein. The reference herein to a crystalline zeolitic molecular sieve substantially free of any catalytic loading metal or metals means that the molecular sieve component-contains no more than 0.5 weight percent of nickel or cobalt, and no more than 0.1 weight percent platinum or palladium, based on the molecular sieve component.

It will be noted that the weight ratio of catalytic metal in the matrix portion of the catalyst to catalytic metal in the molecular sieve portion of the catalyst is high, in the catalysts of the present invention.

Another particular embodiment of the catalyst of the present invention is a catalyst consisting essentially of:

(A) A porous Xerogel consisting essentially of: (a) at least 15 weight percent silica; (b) alumina, in an amount providing an alumina-to-silica weight ratio of 15/85 to 80/20; (c) nickel, in the form of the metal, oxide, sulfide or any combination thereof, in an amount of 0.01 to 15 weight percent of said Xerogel, calculated as metal; and (d) titanium oxide, in an amount of l to 10 weight percent of said Xerogel, calculated as metal;

(B) A crystalline zeolitic molecular sieve, in an amount of 1 to 50 weight percent of said catalyst, said molecular sieve being in the form of particles, said particles being disposed through said Xerogel; said catalyst having an average pore diameter below 100 angstroms and a surface area above 200 square meters per gram.

Still further in accordance with the present invention, there is provided a hydrocracking process which comprises contacting a hydrocarbon feedstock containing substantial amounts of materials boiling above 200 F. and selected from the group consisting of petroleum distillates, solvent-deasphalted petroleum residua, shale oils and coal tar distillates, in a reaction zone with hydrogen and the catalyst described above, at hydrocracking conditions, including a temperature in the range 400 to 950 F., a pressure in the range 800 to 3500 p.s.i.g., a liquid hourly space velocity in the range 0.1 to 5.0, and a total hydrogen supply rate of 200 to 20,000 s.c.f. of hydrogen per barrel of said feedstock, and recovering from said reaction zone valuable products, including gasoline. The hydrocarbon feedstock preferably contains less than 1000 p.p.m. organic nitrogen. A prior hydrofining step may be used, if desired, to reduce the feed nitrogen content to the preferred level; however, because of the superior nitrogen tolerance of the molecular sieve component, compared with silica-alumina gel, the hydrofining step need not accomplish complete nitrogen content reduction, as further discussed hereinafter.

Further in accordance with the present invention, advantageous results are obtained by providing in the reaction zone, in addition to said catalyst, a separate second catalyst comprising a hydrogenating component selected from Group VI metals and compounds thereof, a hydrogenating component selected from Group VIII metals and compounds thereof, and a component selected from the group consisting of alumina and silicaalumina. Further in accordance with the present invention, said separate second catalyst may be located in said reaction zone in a bed disposed above said catalyst comprising a molecular sieve component. In the embodiments of the present invention discussed in this paragraph, no other prior hydrofining step generally will be necessary, because hydrofining is accomplished in one reaction zone concurrently with hydrocracking, together with some hydrogenation of aromatics.

Still further in accordance with the present invention, there is provided a hydrocracking process which comprises sequentially contacting a hydrocarbon feedstock and hydrogen with a first bed of catalyst and then with a second bed of catalyst, said catalyst beds both being located within a single elongated reactor pressure shell, said first bed of catalyst being located in an upper portion of said shell, the catalyst of said first bed comprising a hydrogenating component selected from the group consisting of Group VI metals and compounds thereof and Group VIII metals and compounds thereof, and a component selected from the group consisting of alumina and silica-alumina, the catalyst of said second bed comprising the molecular sieve-containing catalyst of the present invention, maintaining said first bed of catalyst and said second bed of catalyst at a temperature in the range 400 to 950 F. and a pressure in the range 800 to 3500 p.s.i.g. during said contacting, maintaining the total supply rate of said hydrogen into said reactor shell from 200 to 20,000

s.c.f. of hydrogen per barrel of said feedstock, and recovering a gasoline product from the efiluent of said second bed of catalyst.

The hydrocracking zone of the process of the present invention may be operated once through, or advantageously may be operated by recycling thereto materials from the efiluent thereof that boil above 200 F., preferably above 400 P. All or a portion of these heavier materials advantageously may be catalytically cracked. The heavy gasoline fraction from the hydrocracking zone advan tageously may be catalytically reformed.

HYDROCARBON FEEDSTOCKS The feedstocks supplied to the hydrocracking zone containing a catalyst comprising a crystalline zeolitic molecular sieve component in the process of the present invention are selected from the group consisting of petroleum distillates, solvent-deasphalted petroleum residua, shale oils and coal tar distillates. The feedstocks contain substantial amounts of materials boiling above 200 F., preferably substantial amounts of materials boiling in the range 350 to 950 F., and more preferably in the range 400 to 900 F. Suitable feedstocks include those heavy distillates normally defined as heavy straight-run gas oils and heavy cracked cycle oils, as well as conventional FCC feed and portions thereof. Cracked stocks may be obtained from thermal or catalytic cracking of various stocks, including those obtained from petroleum, gilsonite, shale and coal tar. As discussed hereinafter, the feedstocks may have been subjected to a hydrofining and/ or hydrogenation treatment, which may have been accompanied by some hydrocracking, before being supplied to the hydrocracking zone containing the catalyst comprising a crystalline zeolitic molecular sieve.

NITROGEN CONTENT OF FEEDSTOCK While the process of the present invention can be practiced with utility when supplying to the hydrocracking zone containing the catalyst comprising a crystalline zeolitic molecular sieve component, hydrocarbon feeds containing relatively large quantities of organic nitrogen, for example several thousand parts per million organic nitrogen, it is preferred that the organic nitrogen content be less than 1000 parts per million organic nitrogen. A preferred range is 0.5 to 1000 parts per million; more preferably, 0.5 to 100 parts per million. As previously discussed, a prior hydrofining step may be used, if desired, to reduce the feed nitrogen content to the preferred level. The prior hydrofining step advantageously may also accomplish hydrogenation and a reasonable amount of hydrocracking. Because of the superior tolerance for organic nitrogen compounds of the molecular sieve component of the catalyst of the present invention compared with silica-alumina gel, the hydrofining step need not accomplish complete organic nitrogen content reduction. Further, because of the superior tolerance of the molecular sieve component for ammonia, compared with silica-alumina gel, and because the molecular sieve component is more tolerant of ammonia than of organic nitrogen compounds, ammonia produced in the hydrofining zone either may be removed from the system between the hydrofining zone and the hydrocracking zone containing the hydrocracking catalyst comprising a molecular sieve component, or may be permitted to pass into the hydrocracking zone along with the feed thereto.

SULFUR CONTENT OF FEEDSTOCKS While the process of the present invention can be practiced with utility when supplying to the hydrocracking zone containing a catalyst comprising a molecular sieve component, hydrocarbon feeds containing relatively large quantities of organic sulfur, it is preferable to maintain the organic sulfur content of the feed to that zone in a range of 0 to 3 weight percent, preferably 0 to 1 weight percent.

CATALYST COMPRISING A CRYSTALLINE ZEO LITIC MOLECULAR SIEVE COMPONENT AND PREPARATION THEREOF (A) General The crystalline zeolitic molecular sieve component of the hydrofining-hydrocracking catalyst may be of any type that is known in the art as a useful component of a conventional hydrocracking catalyst containing a crystalline zeolitic molecular sieve component. A decationized molecular sieve cracking component is preferred. Especially suitable are faujasite, particularly Y type and X type faujasite, and mordenite, in the ammonia or hydrogen form.

(B) Method of preparation The molecular sieve component of the catalyst may be prepared by any conventional method known in the art.

The molecular sieve component may be dispersed in a matrix of the other catalyst components by cogelation of said other components around said molecular sieve component in a conventional manner.

The molecular sieve component, substantially in the ammonia or hydrogen form, may be maintained substantially free of any catalytic loading metal or metals, as required by the present invention, by dispersing the molecular sieve component in a slurry of the precursors of the other catalyst components at a pH of 5 or above. When a sodium form of molecular sieve component is one of the starting materials, it may be converted to the ammonia or hydrogen form by ion exchange prior to being combined with the other catalyst components. A1 ternatively, it may be combined with the other catalyst components and then converted to the ammonia or hydrogen form by ion exchange. In either case, the molecular sieve component should not be combined with the precursors of the other catalyst components at a pH below 5.

The catalyst, in hydrogel form, is dried in a conventional manner, and then desirably is activated in an oxygen-containing gas stream for 1 to hours at 900 to 1600 F., preferably 2 to 8 hours at 1200 to 1500 F.

The finished catalyst may be sulfided in a conventional manner prior to use, if desired. If not presulfided, the catalyst will tend to become sulfided during process operation from any sulfur content that may be present in the hydrocarbon feed.

SEPARATE HYDROFINING CATALYST (A) General As previously indicated, advantageous results are obtained by providing in the reaction zone containing the hydrocracking catalyst comprising a molecular sieve component a separate second catalyst comprising a hydrogenating component selected from Group VI metals and compounds thereof, a hydrogenating component selected from Group VHI metals and compounds thereof, and a support selected from the group consisting of alumina and silica-alumina. Pellets or other partciles of this separate second catalyst may be physically mixed with the hydrocracking catalyst comprising a molecular sieve component, but preferably are disposed in a separate catalyst bed located ahead of the hydrocracking catalyst in the same reactor shell, eliminating interstage condensation, pressure letdown and ammonia and hydrogen sulfide removal. In a preferred arrangement using downfiow of hydrocarbon feed, the bed of separate second catalyst is located above the hydrocracking catalyst in the same reactor shell.

Where said separate second catalyst is located in the same reactor shell as the hydrocracking catalyst containing a molecular sieve component, it is preferbly present in an amount in the range of 10 to volume percent of the total amount of catalyst in the reactor.

In an arrangement less preferred than the ones discussed above in this section, the separate second catalyst may be located in a separate hydrofining reactor, operated under conventional hydrofining conditions, from the efiluent of which ammonia or hydrogen sulfide, or both, and also hydrocarbon products, if desired, may be removed prior to hydrocracking the remaining hydrofined feedstock in a subsequent hydrocracking reactor.

In any of the arrangements discussed in this section, the separate second catalyst preferably has hydrofining activity and hydrogenation activity, and even more preferably also has enough hydrocracking activity to convert 0.2 to 50, preferably 5 to 20, weight percent of the hydrocarbon feedstock to products boiling below the initial boiling point of the feedstock in a single pass. The hydrogenation activity preferably is sufiicient to saturate or partially saturate a substantial portion of the organic oxygen, nitrogen and sulfur compounds in the feed to water, ammonia, and hydrogen sulfide.

Preferably, said separate second catalyst contains nickel or cobalt or compounds thereof in an amount of l to 15 weight percent, calculated as metal, and molybdenum or tungsten or compounds thereof in an amount of 5 to 30 weight percent, calculated as metal, with the remainder of the catalyst consisting of alumina, or silicaalumina containing up to 50 weight percent silica.

Particularly preferred examples of said separate second catalyst, comprising silicia-alumina, are:

Percent by weight of total catalyst, calculated as metal SiO2/Al20 Ni Mo W weight ratio (B) Method of preparation Said separate second catalyst may be prepared by any conventional preparation method, including impregnation of an alumina or silica-alumina support with salts of the desired hydrogenating component, or cogelation of all components, with the latter method being preferred.

The hydrocracking catalyst comprising a molecular sieve component has activity and stability advantages over a conventional hydrocracking catalyst. It has been found that use of said separate second catalyst in the above-described arrangements further increases the stability of the hydrocracking catalyst containing a molecular sieve component, compared with the stability of the latter catalyst when the identical feed thereto has not been first or concurrently processed in the presence of said sep arate second catalyst.

OPERATING CONDITIONS The hydrocracking zone containing the catalyst com prising a molecular sieve component is operated at hydrocracking conditions including a temperature in the range 400 to 950 F., preferably 500 to 850 F., a pressure in the range 800 to 3500 p.s.i.g., preferably 1000 to 3000 p.s.i.g., a liquid hourly space velocity in the range .1 to 5.0, preferably 0.5 to 5.0, and more preferably 0.5 to 3.0. The total hydrogen supply rate (makeup and recycle hydrogen) to said zone is 200 to 20,000 s.c.f., preferably 2000 to 20, s.c.f., of hydrogen per barrel of said feedstock.

Where a separate hydrofining zone, which also may accomplish hydrogenation and some hydrocracking, is located ahead of the hydrocracking zone containing a catalyst containing a molecular sieve component, the operating conditions in the separate hydrofining zone include a temperature of 400 to 900 F., preferably 500 to 800 F., a pressure of 800 to 3500 p.s.i.g., preferably 1000 to 2500 p.s.i.g., and a liquid hourly space velocity of 0.1 to 5.0, preferably 0.5 to 3.0. The total hydrogen supply rate (makeup and recycle hydrogen) is 200 to 20,000 s.c.f. of hydrogen per barrel of feedstock, preferably 2000 to 20,000 s.c.f. of hydrogen per barrel of feedstock.

Where a separate bed of hydrofining catalyst is located above a bed of the hydrocracking catalyst containing a molecular sieve component in the same reactor shell, the space velocity through the bed of hydrofining catalyst will be a function of the space velocity through the hydrocracking catalyst bed and the amount of hydrofining catalyst expressed as a volume percent of the total cata lyst in the reactor. For example, where the hydrofining catalyst is 25 volume percent of the total catalyst in the reactor, and the space velocity through the bed of hydrocracking catalyst is 0.9, the space velocity through the bed of hydrofining catalyst will be 2.7. Accordingly, the space velocity through the bed of hydrofining catalyst in the process of the present invention may range from 0.15 to 45.0.

The operating conditions in the reforming zone and catalytic cracking zone employed in various embodiments of the present invention are conventional conditions known in the art.

PROCESS OPERATION WITH REFERENCE TO DRAWING Referring now to FIG. 1 of the drawing, in accordance with a primary embodiment of the present invention, a hydrocarbon feedstock as previously described, which in this case may boil above 400 F., is passed through line 1 into hydrocracking zone 2, which contains a hydrocracking catalyst consisting of a molecular sieve component substantially free of any catalytic loading metal, dispersed in a gel matrix consisting of a silica-alumina gel and a nickel hydrogenation component. As previously discussed, a separate second catalyst, previously described, may be located in hydrocracking zone 2. The feedstock is hydrocracked in hydrocracking zone 2 at conditions previously discussed, in the presence of hydrogen supplied through line 3. From hydrocracking zone 2 an efiluent is withdrawn through line 4, hydrogen is separated therefrom in separator 5, and hydrogen is recycled to hydrocracking zone 2 through line 6. From separator 5, hydroeracked materials are passed through lines 7 and 8 to distillation column 9, where they are separated into fractions, including a C fraction which is withdrawn through line 10, a C l80 F. fraction which is withdrawn through line 11, and a l80400 P. fraction which is withdrawn through line 12.

Still referring to FIG. 1, in accordance with another embodiment of the present invention, the 180400 F. fraction in line 12 is reformed under conventional catalytic reforming conditions in reforming zone 13, from which a catalytic reformate is withdrawn through line 14.

Still referring to FIG. 1, in accordance with another embodiment of the present invention, a hydrocarbon feedstock which is to be hydrofined and/or hydrogenated, and partially hydrocraeked, if desired, in a separate hydrotreating zone prior to being hydrocracked in hydrocracking zone 2, is passed through line 15 to hydrotreating zone 16 containing a catalyst, as previously described, having hydrofining and/0r hydrogenation activity. The feedstock is hydrotreated in zone 16 at conditions previously described, in the presence of hydrogen supplied through line 17. The effluent from hydrotreating zone 16 is passed through line 18 to separation zone 19, from which hydrogen separated from the treated feedstock is recycled through line 20 to hydrotreating zone 16. In zone 19, water entering through line 21 is used to scrub ammonia and other contaminants from the incoming hydrocarbon stream, and the ammonia, water and other contaminants are withdrawn from zone 19 through line 22.

Referring now to FIG. 2, a hydrocarbon feedstock, as previously described, which in this case may boil above 400 F., is passed through line 29 to hydrotreating zone 30 containing a catalyst, as previously described, having hydrofining and/or hydrogenation activity. The feedstock is hydrofined and/or hydrogenated, and partially hydrocracked, if desired, in zone 30, at conditions previously described, in the presence of hydrogen supplied through line 31. The eflluent from zone 30 is passed through line 32, without intervening impurity removal, into hydrocracking zone 33, where it is hydrocracked in the presence of a hydrocracking catalyst consisting of a molecular sieve component substantially free of any catalytic loading metal, dispersed in a gel matrix consisting of a silicaalumina gel and a nickel hydrogenating component. A separate second catalyst may be present in zone 33, as described in connection with zone 2 in FIG. 1. Hydrotreating zone 30 and hydrocracking zone 33 may be located in separate reactor shells, which may be operated at different pressures. Alternatively, and in a preferred manner of operation, hydrotreating zone 30 and hydrocracking zone 33 may be separate catalyst beds located in a single pressure shell 34, and the eflluent from zone 30 may be passed to zone 33 without intervening pressure letdown, condensation or impurity removal. The effluent from zone 33 is passed through line 35 to separation zone 36, from which hydrogen is recycled through line 37 to hydrotreating zone 30. All or a portion of the recycled hydrogen may be passed through line 38 to hydrocracking zone 33, if desired. In separation zone 36, water entering through line 40 is used to scrub ammonia and other contaminants from the incoming hydrocarbon stream, and the ammonia, water and other contaminants are withdrawn from zone 36 through line 41. The efiluent from zone 36 is passed through line 42 to distillation column 43, where it is separated into fractions, including a C fraction which is withdrawn through line 44, a C 180 F. fraction which is withdrawn through line 45, a 180- 400 F. fraction which is withdrawn through line 46, and a fraction boiling above 400 P. which is withdrawn through line 47. The fraction in line 47 may be recycled through lines 48 and 49 to hydrocracking zone 33. All or a portion of the fraction in line 48 may be recycled to hydrotreating zone 30 through line 50, if desired.

Still referring to FIG. 2, in accordance with another embodiment of the present invention, the 180-400 F. fraction in line 46 may be passed to a catalytic reforming zone 55, where it may be reformed in the presence of a conventional catalytic reforming catalyst under conventional catalytic reforming conditions to produce a catalytic reformate, which is withdrawn from zone through line 56.

Still referring to FIG. 2, in another embodiment of the present invention, all or a portion of the fraction in line 47 may be passed through line 57 to catalytic cracking zone 58, which may contain a conventional catalytic cracking catalyst and which may be operated under conventional catalytic cracking conditions, and from which a catalytically cracked effluent may be withdrawn through line 59.

EXAMPLES The following examples are given for the purpose of further illustrating the practice of the process of the present invention. However, it is to be understood that these examples are given by way of exemplification only, and are not intended in any way to limit the scope of the present invention.

EXAMPLE 1 A cogelled catalyst (catalyst A) of the following composition was prepared.

Wt. percent of Component: total catalyst NiO 11.4 ZI'Og 9.0 A1 27.0 SiO 42.6

Crystalline Zeolitic molecular sieve, Y form 10.0

Total 100.0

The catalyst was prepared by the following steps, using sufiicient quantities of the various starting materials to produce the above-indicated Weight percentages of the components of the final catalysts:

(1) An aqueous acidic solution was prepared, containing AlCl ZrOCl NiCl and acetic acid.

(2) Two alkaline solutions were prepared: (1) a sodium silicate solution; and (2) an ammonia solution containing sulficient excess ammonia so that upon combining the alkaline solutions with the acidic solution coprecipitation of all of the metal-containing components would occur at a neutral pH of about 7.

(3) The acidic and alkaline solutions were combined, and coprecipitation of all of the metal-containing components of the solutions occurred at a pH of about 7, resulting in a slurry.

(4) Linde sodium Y crystalline zeolitic molecular sieve in finely divided form was added to the slurry.

(5) The molecular sieve-containing slurry was filtered to produce a molecular sieve-containing hydrogel filter cake, which was washed repeatedly with dilute ammonium acetate solution, to remove sodium and chloride ionic impurities from both the hydrogel and the molecular sieve contained therein.

(6) The molecular sieve-containing hydrogel was dried in an air-circulating oven and then was activated in flowing air for approximately 3 hours at 1350 F.

The finished catalyst was characterized by a surface area.

above 395 m. /g., a pore volume of 0.33 cc./g., an average pore diameter of 33.5 angstroms, and a molecular sieve component substantially free of catalytic metals; that is, substantially all of the nickel in the catalyst was located in the gel portion of the catalyst rather than in the molecular sieve component thereof.

EXAMPLE 2 EXAMPLE 3 A cogelled catalyst (catalyst C, a comparison catalyst) of the following composition was prepared:

Component: Wt. percent of total catalyst MO in gel component 8.9 MO in sieve component 1.3 A1 0 21.0 SiO 40.1 Crystalline zeolitic molecular sieve, Y form 28.7

Total 100.0

The catalyst was prepared as in Example 1, except that prior to incorporation in the slurry the molecular sieve was presoaked in a dilute solution of NiCl whereby the molecular sieve was loaded with nickel in an amount which resulted in the aforesaid amount of NiO associated with the molecular sieve in the final catalyst.

EXAMPLE 4 Portions of catalysts A and C of Examples 1 and 3, respectively, were separately used to hydrocrack separate portions of a mildly hydrofined California cycle oil feedstock, on a once-through basis.

The cycle oil feedstock had the following characteristics:

Starting temperature, F. As indicated below.

The hydrocracking activities of the two catalysts, as measured by the starting temperatures necessary to achieve the indicated per-pass conversion, and the fouling rates of the two catalysts, as indicated by the hourly rise in temperature necessary to maintain the indicated perpass conversion, were:

Catalyst A Catalyst 0 Starting T, F 654 655 Fouling rate, F./h1' 0. 03 0.05

Catalyst B is used to hydrocrack the same feedstock, at the same conditions. The results are:

Catalyst B Starting T, F. 665 Fouling Rate, F./hr. 0.03

From the foregoing examples it may be seen that catalyst A, containing a molecular sieve component substantially free of catalytic metal, had a lower fouling rate and a lower starting temperature than comparison catalyst C, and that its starting temperature is considerably lower than that of comparison catalyst B.

EXAMPLE 5 The catalyst of Example 1 is used to hydrocrack a light cycle oil hydrocarbon feedstock of the following description:

Gravity, API 19.5 Aniline point, F. 62 Sulfur content, weight percent 0.43 Nitrogen content, p.p.m. 330 Aromatics content, liquid volume percent 70 Boiling range, ASTM D-1160 distillation:

ST/S 381/471 10/30 492/532 50 568 70/90 598/635 /EP 648/681 The hydrocracking is accomplished, on a once-through basis, at an average catalyst temperature of 735 F., a pressure of 2100 p.s.i.g, a liquid hourly space velocity of 0.9, and a hydrogen supply rate of 12,000 s.c.f. per barrel of hydrocarbon feedstock. The hydrogen consumption is 2000 s.c.f. per barrel of hydrocarbon feedstock.

The product distribution is as follows:

Wt. percen C 0.1 C 0.3 C 2.8 iC 4.6 I1C4 4.4

Wt. percent C 180 F. 11.0 180400 F. 34.0 400 F.+ 46.0

The 180400 F. portion of the product is characterized by a gravity of 40 API and by a paraffin/naphthene/aromatic ratio of /35/50.

The 400 F.+ portion of the product is characterized by a gravity of API and by an aniline point of 98.0 F.

EXAMPLE 6 The 180400 F. portion of the product of Example 5 is catalytically reformed, using a conventional reforming catalyst and conventional reforming conditions, and is found to be a superior feedstock for this operation. The catalytic reformate is combined with the C 180 F. portion of the product of Example 5, to produce a gasoline pool. When 0.; hydrocarbons are blended into this gasoline pool in an amount sufficient to provide a pool H Reid vapor pressure of 10, while conducting the reforming to provide a 91 F-l clear pool octane number, the total gasoline pool is 58 liquid volume percent of the light cycle oil feedstock hydrocracked in Example 5. I.e., in this operation a 58 liquid volume percent yield, based on the hydrocracking zone feed, of a 91 F-l clear gas oline having a Reid vapor pressure of 10, is obtained.

EXAMPLE 7 The 400 F.+ portion of the product of Example 5, characterized by a gravity of 30 API and by an aniline point of 980 F., is recycled to the catalytic cracking unit which produced the light cycle oil feed used in Example 5. This upgrades the total feed to the catalytic cracking unit, and causes decreased coke production and increased gasoline production in that unit. These improved results are made possible because of the improved characteristics of the 400 F.+ materials recycled from the hydrocracking zone to the catalytic cracking unit, compared with the approximately 400 F.+ light cycle oil supplied to the hydrocracking zone from the catalytic cracking unit:

EXAMPLE 8 A catalyst prepared exactly as in Example 1, and having the same composition as the catalyst of Example 1, is used to hydrocrack another portion of the same light cycle oil hydrocarbon feedstock described in Example 5.

The hydrocracking is accomplished on a recycle basis, that is, with the 400 F.+ portion of the product being recycled to the hydrocracking zone, at an average catalyst temperature of 760 F., a total pressure of 2100 p.s.i.g., a liquid hourly space velocity of 0.9, and a total hydrogen supply rate of 5500 s.c.f. per barrel of hydrocarbon feedstock.

The product distribution is as follows:

The 180-400 F. portion of the product is characterized by a gravity of 41 API and by a parafiin/naphtheme/aromatic ratio of 17/31/52.

12 EXAMPLE 9 The 180-400 F. portion of the product of Example 8 is catalytically reformed, using a conventional reforming catalyst and conventional reforming conditions, and is found to be a superior feedstock for this operation. The catalytic reformate is combined with the C l F. portion of the product of Example 8, to produce a gasoline pool. When C hydrocarbons are blended into this gasoline pool in an amount sufiicient to provide a pool Reid vapor pressure of 10, while conducting the reforming to provide a 91 F-l clear pool octane number, the total gasoline pool is liquid volume percent of the light cycle oil feedstock hydrocracked in Example 8. Le, in this operation a 105 liquid volume percent yield, based on the hydrocracking zone light cycle oil feed, of 91 F-l clear gasoline having a Reid vapor pressure of 10, is obtained.

EXAMPLE 10 A first bed of hydrocracking catalyst prepared exactly as in Example 1, and having the same composition as the catalyst of Example 1, is placed in a reactor. A second bed of catalyst is placed in the reactor above the first bed. The volume of the second bed is 25% of the total catalyst volume. The catalyst in the second bed, prepared by coprecipitation of metals and silica-alumina-titauia gel, has the following composition:

Wt. percent NiO 12.7 W0 12.6

A1 0 30.0 TiO 10.0

Total 100.0

Another portion of the same light cycle oil feedstock described in Example 5 is passed downwardly through both catalyst beds in the reactor together with added hydrogen, the hydrogen and cycle oil sequentially contacting the catalyst beds, with no product or impurity removal between beds, at the following conditions:

The portion of the product boiling above 400 F. is recycled to the reactor. The hydrogen consumption is 2700 s.c.f. per barrel of hydrocarbon feedstock (fresh feedstock).

The product distribution of the 400 F.- product is as follows:

Wt. percent C 0.3 C 0.9 C 4.0 iC 5.4 nC 4.3 C 400 F. 89.0

EXAMPLE 11 The 180-400 F. portion of the product of Example 10 is catalytically reformed, using a conventional reforming catalyst and conventional reforming conditions, and is found to be a superior feedstock for this operation. The catalytic reformate is combined with the C --180 F. portion of the product of Example 10 to produce a gasoline pool. When C hydrocarbons are blended into this gasoline pool in an amount sufiicient to provide a pool Reid vapor pressure of 10, while conducting the reforming to provide a 91 F-l clear pool octane number, the total gasoline pool is 117 liquid volume percent of the light cycle oil feedstock hydrocracked in Example 10. Le, in this operation a 117 liquid volume percent yield, based on the fresh hydrocarbon feed to the reactor in Example 10, of a 91 F-l clear gasoline having a Reid vapor pressure of 10, is obtained.

EXAMPLE 12 The run of Example is repeated exactly, except using the catalyst of Example 1 unaccompanied in the reactor by a bed of hydrogenation catalyst. The average catalyst temperature needed to obtain the same per-pass conversion is 810 F., compared with 760 F. in Example 10, thereby indicating that the process of the present invention may be further improved by hydrotreating the feedstock prior to hydrocracking it in the presence of the molecular sieve-containing catalyst of the present invention.

Although only specific embodiments of the present invention have been described, numerous variations can be made in these embodiments without departing from the spirit of the invention, and all such variations that fall within the scope of the appended claims are intended to be embraced thereby.

What is claimed is:

1. A hydrocarbon conversion catalyst consisting essentially of:

(A) A gel matrix consisting essentially of:

(a) a gel selected from silica-alumina gel, silicaalumina-titania gel and silica-alumina-zirconia gel, and

(b) at least one hydrogenating component selected from Group VIII metals and compounds thereof; and

(B) A crystalline zeolitic molecular sieve substantially in the ammonia or hydrogen form, substantially free of any loading metal or metals, said molecular sieve further being in particulate form and being dispersed through said matrix; said catalyst further being characterized by an average pore diameter below 100 angstroms and a surface area above 200 square meters per gram.

2. A catalyst as in claim 1, wherein said matrix contains at least 15 weight percent silica, and contains alumina in an amount providing an alumina-to-silica weight ratio of 15/85 to 80/20.

3. A catalyst as in claim 1, wherein said molecular sieve is present in an amount of 1 to weight percent, based on said catalyst.

4. A catalyst as in claim 1, wherein said Group VIII hydrogenating component is present in an amount of 0.01 to 15 weight percent, based on said catalyst and calculated as metal.

5. A catalyst as in claim 1, wherein said matrix contains a silica-alumina-titania gel or a silica-alumina-zirconia gel, and wherein the titania or zirconia is present in an amount of 1 to 15 weight percent of said matrix, calculated as metal.

6. A catalyst consisting essentially of (A) A porous Xerogel consisting essentially of:

(a) at least 15 weight percent silica,

(b) alumina, in an amount providing an aluminato-silica weight ratio of 15/ 85 to 80/20,

(c) nickel, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 0.01 to 15 weight percent of said Xerogel, calculated as metal;

(d) titanium oxide, in an amount of 1 to 10 weight percent of said Xerogel, calculated as metal;

(B) A crystalline zeolitic molecular sieve, substantially free of any loading metal or metals, and substantially in the ammonia or hydrogen form, in an amount of 1 to 50 weight percent of said catalyst, said molecular sieve being in the form of particles, said particles being dispersed through said Xerogel; said catalyst having an average pore diameter below angstroms and a surface area above 200 square meters per gram.

7. A hydrocracking process which comprises contacting a hydrocarbon feed containing substantial amounts of materials boiling above 200 F. and selected from the group consisting of petroleum distillates, solvent-deasphalted petroleum residua, shale oils and coal tar distillates, in a reaction zone with hydrogen and the catalyst of claim 1, at hydrocracking conditions including a temperature in the range 400 to 950 F., a pressure in the range 800 to 3500 p.s.i.g., a liquid hourly space velocity in the range 0.1 to 5.0, and a total hydrogen supply rate of 200 to 20,000 s.c.f. of hydrogen per barrel of feedstock, and recovering hydrocracked products from said reaction zone.

8. A process as in claim 7, wherein said hydrocarbon feed contains 0.5 to 1000 ppm. nitrogen.

9. A process as in claim 7, wherein said reaction zone contains, in addition to said catalyst, a separate second catalyst comprising a hydrogenating component selected from Group VI metals and compounds thereof, a hy drogenating component selected from Group VIII metals and compounds thereof, and a component selected from the group consisting of alumina and silica-alumina.

10. A process as in claim 9, wherein said separate second catalyst is located in said reaction zone in a bed disposed above said catalyst containing a molecular sieve component.

11. A hydrocracking process which comprises sequentially contacting a hydrocarbon feedstock and hydrogen with a first bed of catalyst and then with a second bed of catalyst, said catalyst beds both being located within a single elongated reactor pressure shell, said first bed of catalyst being located in an upper portion of said shell, the catalyst of said first bed comprising a hydrogenating component selected from the group consisting of Group VI metals and compounds thereof and Group VIII metals and compounds thereof and a component selected from the group consisting of alumina and silica-alumina, the catalyst of said second bed being the catalyst of claim 1, maintaining said first bed of catalyst and said second bed of catalyst at a temperature in the range 400 to 950 F. and a pressure in the range 800 to3500 p.s.i.g. during said contacting, maintaining the total supply rate of hydrogen into said reactor shell from 200 to 20,000 s.c.f. of hydrogen per barrel of said feedstock, and recovering a gasoline product from the efiiuent from said second bed of catalyst.

12. A process as in claim 11 wherein the effiuent from said second bed of catalyst is separated into fractions, including a light gasoline fraction, a heavy gasoline fraction, and a fraction boiling generally higher than said heavy gasoline fraction.

13-. A process as in claim 12 wherein said heavy gasoline fraction is catalytically reformed.

14. A process as in claim 12 wherein said fraction boiling generally higher than said heavy gasoline fraction is catalytically cracked.

References Cited UNITED STATES PATENTS 5/1964 Kelley et al 20860 7/1964 Plank et al 208-- US. Cl. X.R.

2 3 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 ,535 ,225 Dated October 20 1970 Invent l'( JOSEPH JAFEE It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. 2, line 25, after "zirconia" and before "g" insert --gel--.

Col. 6 line 75, "20" should read --20 ,000-.

C01. 10, line 18, "1800" should read --80OU-.

Signed and sealed this 9th day or June 1971 (SEAL) Attest:

EDWARD M.FLETCHER,JR. WILLIAM E. SGHUYLER, JR. Attesting Officer Commissioner of Patents 

